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1 USTER LABORATORY SYSTEMS APPLICATION REPORT Quality management in the textile laboratory THE STANDARD FROM FIBER TO FABRIC Gabriela Peters November 2003 / Edition 2: November 2007 SE 577
2 Copyright 2007 by Uster Technologies AG All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, translated or transmitted in any form or by any means, electronically, mechanically, photocopying, recording or otherwise, without the prior permission in writing of the copyright owner. veronesi\tt\schulung_dokumente\ Off-Line\Laborsysteme\SE_577_Quality management in the textile laboratory 2 (16) USTER PRODUCTS
3 Contents 1 Introduction Size of the spinning mill and number of production machines5 3 Sample testing Test conditions and sample size Combination of on-line and off-line tests Test frequency, individual processes Influence of the relative humidity in the test room Summary USTER PRODUCTS 3 (16)
4 4 (16) USTER PRODUCTS
5 1 Introduction Quality management in the textile laboratory is of central importance to the spinning mill because production faults can be identified and eliminated with the test results. A question is often asked these days as to how often a machine has to be monitored and which machines must be monitored most carefully. It can be said with 100% certainty that a fault in the spinning preparation is considerably more serious than a defective cylinder on an individual ring spinning position. The crucial machine in a spinning mill with regard to fiber and yarn neps is the card, the saying the card is the heart of a spinning mill is not said without reason. The raw material selection plays an equally important role but this report covers only the spinning process in order to find production faults. 2 Size of the spinning mill and number of production machines A ring spinning mill with 30,000 spindles was the basis for the calculation of the test frequency in a laboratory. This spinning mill produces combed cotton yarns. The following machines are needed for the plant: Blow room 2 Card 3 Drawing frame 4 Comber lap 5 Comber 6 Drawing frame 7 Roving frame 8 Ring frame 9 Winder Number of processes Fig. 1 Process steps and number of machines in a spinning mill The number of corresponding machines from the blowroom to the final drawframe is mentioned in Fig. 1. The spindles and winding position are mentioned for the flyer, the ring spinning and winding machine. USTER PRODUCTS 5 (16)
6 3 Sample testing A lot could be written or cited about tests but tests should actually be simple and practical. A systematic sample testing of each machines has asserted itself in most spinning mills. There is the assumption that each process step in the spinning mill will be monitored during a certain period of time. This is not difficult for the process from the card to the finisher drawframe because the cards should always be checked once a week. The test period of a roving frame and a ring spinning machine takes considerably longer because each individual spindle has to be checked once over a certain period of time. In our example there are 600 spindles on the roving frame which is equivalent to five to six machines depending on the type of spindles. If ten or eight spindles of a roving frame are removed and tested from the same roving frame every second day, it would take a whole month to test all the spindles on the flyer. It also needs to be considered that there are 30 ring spinning machines in our example. The laboratory staff would have to check 120 spindles daily if we assume a single shift and 250 working days per year. This would mean that ten bobbines have to be sampled every third day from the very same spinning machine. This calculation does not include the time needed for collecting the samples. A rotor spinning plant has ten rotor spinning machines on average which is equivalent to around 3,000 rotors, depending on the manufacturer. If ten cones are taken from each rotor spinning machine every day and checked, it would take about one and a half month to check the whole rotor spinning mill. The interval for checking rotor spinning machines is actually shorter than the one for ring spinning machines. However, considerably more yarn is produced on a rotor spinning position during a given interval which means that significantly more checks have to be made on each rotor spinning position. As the period of one year is extremely long between checks on ring spinning machines, most spinning mills have two shifts in order to shorten this test period. A defective spindle on a ring spinning machine results in considerably less subsequent defects than a defective machine in spinning preparation. Therefore, it has to be considered in the test frequency that the process from the card to the combing machine has to be checked far more intensively. This is normally no problem because there are considerably less production positions. The test frequency is described in chapter 6. 6 (16) USTER PRODUCTS
7 4 Test conditions and sample size The following table shows the test conditions and sample size for the individual quality characteristics. Quality characteristics Name Unit Instrument Number of samples Test within Testing speed [m/min] Micronaire Mic USTER HVI SPECTRUM 1 5 Upper Half UHML mm USTER HVI SPECTRUM 1 5 Mean Length UI % USTER HVI SPECTRUM 1 5 Bundle strength Strength g/tex USTER HVI SPECTRUM 1 5 Color RD % USTER HVI SPECTRUM 1 5 +b 1 5 Trash CNT USTER HVI SPECTRUM 1 5 Area % 1 5 /g 1/g USTER AFIS PRO 1 5 SCN/g 1/g 1 5 Length SFC(n) % USTER AFIS PRO 1 5 SFC(w) % 1 5 UQL(w) mm 1 5 Maturity Fine mtex USTER AFIS PRO 1 5 IFC % 1 5 Mat 1 5 Trash Trash/g 1/g USTER AFIS PRO 1 5 Dust/g 1/g 1 5 VFM % 1 5 Count variation CV cb % USTER TESTER 4 FA Module 10 1 Mass variation CV m % USTER TESTER CV mb % Hairiness H USTER TESTER s H CV Hb % Imperfections Thin places 1/1000 m USTER TESTER Thick places 1/1000 m /1000 m Trash and dust Trash 1/1000 m USTER TESTER Variation diameter Strength HV strength Table 1 Dust 1/1000 m CV d % USTER TESTER Shape Dichte g/cm F H cn USTER TENSORAPID R H cn/tex CV RH % ε H % CVε H % W H cncm CV WH % F H cn USTER TENSOJET R H cn/tex CV RH % ε H % CVε H % W H cncm CV WH % F P=0,1 cn ε P=0,1 % Testing time [min] USTER PRODUCTS 7 (16)
8 5 Combination of on-line and off-line tests Due to the technical progress, it makes sense to choose a combination of on-line and off-line tests in today s spinning mills because laboratory tests only are not sufficient for today s high production quantities: the sample size is insufficient and, therefore, rare, disturbing faults are not detected, and as a consequence, not eliminated. However, there are three reasons why not all tests can be made on-line: a. The presentation of the fibers for example makes it extremely difficult to test on-line in spinning preparation. The ring spinning machine with more than 1,000 spindles is not yet suitable for carrying out complete on-line tests. b. It is only possible to test certain quality characteristics on-line such as evenness. There are quality parameters, which cannot yet be tested on-line, such as all strength and elongation tests. Further, fiber neps in slivers and the short fiber content cannot yet be tested on-line. c. The third and probably the most important reason is the climate. Tests in a laboratory are generally made at a standard climate whilst the climate on a testing position on a machine is not constant and does not correspond to the standard climate. Therefore, tests made in a laboratory are unsurpassed with regard to their accuracy and reproducibility. Thus, it is recommended to find a suitable combination of on-line and offline tests. As already mentioned, it is highly advisable to start with an online measurement from the point of view of today s high production quantities. Therefore, the following examples are always based on on-line monitoring. If there is no on-line monitoring on some machines, the sample size has to be increased for the laboratory tests in order to guarantee that an adequate quantity can be tested. 8 (16) USTER PRODUCTS
9 6 Test frequency, individual processes Combination of on-line and off-line quality management in the blowroom and on the card Test method Quality Fiber Test Sample Equipment characteristics presentation interval size Laydown Fiber strength Micronaire Mat per Laydown 5 Tests USTER HVI OFF-LINE SCI Color Grade Mat per Laydown 5 Tests USTER AFIS Blowroom Trash content Mat once per month 3 Tests Shirley-Analyser OFF-LINE Trash content Fiber neps Mat once per month 5 Tests USTER AFIS Card Sliver count Running ON-LINE CV% 100 m Sliver continuous production USTER SLIVER EXPERT Sliver count Sliver once per week 5 x 10 m USTER AUTOSORTER Table 2 OFF-LINE Diagram Variance-length curve Trash content Sliver Sliver once per week min. 125 m USTER TESTER once per week 5 Tests USTER AFIS Combination of on-line and off-line quality management in the combing process 1. Prozess : Sliver lap machine Test method Quality Fiber Test Sample Equipment characteristics presentation interval size Comber lap OFF-LINE Lap per 3 months 5 Tests USTER AFIS Draw frame Lap count 8 Laps once per week 1 x 1 m Lap balance OFF-LINE Lap per 3 months 5 Tests USTER AFIS Comber Sliver count Sliver once per week 5 x 10 m USTER AUTOSORTER Diagram Sliver once per week min. 125 m USTER TESTER OFF-LINE Variance-length curve Trash content Sliver* once per week 5 Tests USTER AFIS Table 3 Sliver* = The individual comber heads have to be tested if an increase of neps or short fibers of the comber sliver is noted. USTER PRODUCTS 9 (16)
10 Combination of on-line and off-line quality management in the combing process 1. Process: Drawframe Test method Quality Fiber Test Sample Equipment characteristics presentation interval size Drawing frame once per 3 OFF-LINE Sliver 5 Tests USTER AFIS months Comber lap Lap count 8 Laps once per week 1 x 1 m Wickelwaage OFF-LINE Lap once per 3 months 5 Tests USTER AFIS Comber Sliver count Sliver once per week 5 x 10 m USTER AUTOSORTER Diagram Sliver once per week min. 125 m USTER TESTER OFF-LINE Variance-length curve Trash content Sliver* once per week 5 Tests USTER AFIS Table 4 Sliver* = The individual comber heads have to be tested if an increase of neps or short fibers of the comber sliver is noted. Combination of on-line and off-line quality management on the drawframe Test method Quality Fiber Test Sample Equipment characteristics presentation interval size Drawing frame Sliver count Running 1. Passage ON-LINE Sliver continuous production USTER SLIVER EXPERT Sliver count Sliver once per week 5 x 10 m USTER AUTOSORTER OFF-LINE Diagram Sliver once per week 125 m Sliver once per 3 months 5 Tests USTER TESTER USTER AFIS Drawing frame Sliver count Running 2. Passage ON-LINE Sliver continuous production USTER SLIVER EXPERT Sliver count Sliver once per week 5 x 10 m USTER AUTOSORTER Sliver once per week 125 m USTER TESTER OFF-LINE Diagram Sliver once per month 5 Tests USTER AFIS Table 5 Remark: These figures are based on drawframes with autolevellers, perhaps double tests can be reduced. 10 (16) USTER PRODUCTS
11 Combination of on-line and off-line quality management on the roving frame and on the ring spinning machine Test method Quality Fiber Test Sample Equipment characteristics presentation interval size Roving frame Roving count 8 Rovings Every 2. day 1 x 10 m each USTER AUTOSORTER 8 Rovings Every 2. day 1 x 125 m each USTER TESTER OFF-LINE Diagram 8 Rovings once per month 1 Test each USTER AFIS Ring frame Yarn breaks Running ON-LINE Efficiency Bobbins Continuous production USTER RING EXPERT Idle spindles Yarn count CV Yarn count Diagram 10 Bobbins Every 3. day 1 x 100 m each USTER AUTOSORTER OFF-LINE Imperfections Hairiness 10 Bobbins Every 3. day 1 x 400 m each USTER TESTER Yarn diameter Density Trash content Tenacity 20 Tests/Bobbin USTER TENSORAPID 10 Bobbins Every 3. day Elongation 1000 Tests/Bobbin USTER TENSOJET Twist 10 Bobbins once per week 10 Tests/Bobbin Zweigle Classimat Bobbins once per month 100 km USTER CLASSIMAT Table 6 Remark: In case of 30 ring spinning machines, ten bobbins should be removed from different spinning positions every third day. USTER PRODUCTS 11 (16)
12 Combination of on-line and off-line quality management on a winding machine Winder Test method Quality Fiber Test Sample Equipment characteristics presentation interval size Yarn faults N/S/L/T Foreign fibers Pearl chain Running Yarn Continuous Imperfections production USTER QUANTUM Hairiness ON-LINE Number of joints Classification of yarn faults Classification of joint Efficiency Running Production per kg Yarn Continuous production USTER QUANTUM EXPERT Stop time Alarm time Yarn count CV Yarn count 20 Packages Per lot 1 x 100 m each USTER AUTOSORTER Diagram Imperfections 10 Packages Per lot 1 x 400 m each Hairiness OFF-LINE USTER TESTER Yarn diameter Density Trash content Tenacity 10 Packages Per lot 20 Tests/Packages USTER TENSORAPID Elongation USTER TENSOJET Friction 10 Packages Per lot 1 test each Schlafhorst Moisture content 10 Packages Per lot 1 test each Mahlo Table 7 12 (16) USTER PRODUCTS
13 Combination of on-line and off-line quality management on a rotor spinning machine Rotor spinning machine Test method Quality Fiber Test Sample Equipment characteristics presentation interval size Yarn faults N/S/L/T Foreign fibers Moiré, Pearl chain Running Yarn Continuous Imperfections production USTER QUANTUM Hairiness ON-LINE Number of piecers Classification of yarn faults Classification of piecer Efficiency Running Production per kg Yarn Continuous production USTER QUANTUM EXPERT Stop time Alarm time Yarn count CV Yarn count Diagram Imperfections Hairiness 20 Packages 10 Packages once per day once per day one sample of 100 m one sample of 400 m USTER AUTOSORTER USTER TESTER OFF-LINE Yarn diameter Density Trash content Tenacity 10 Packages once per day 20 Tests/package USTER TENSORAPID Elongation USTER TENSOJET Twist 10 Packages once per week 10 Tests/package Zweigle Friction 10 Packages once per month one test each Schlafhorst Moisture content 10 Packages per lot one test each Mahlo Classimat Packages once per week 1000 km USTER CLASSIMAT Table 8 7 Influence of the relative humidity in the test room Material such as cotton, wool or even synthetic fibers absorb a certain amount of water. This water content depends, among other factors, on the relative humidity. The test results of the sensors, the count determination and the strength in particular are influenced by the water content. The following graph shows the influence of the relative humidity on the breaking force of yarns. The temperature was 20 C for all tests. The results, which were measured at 65% humidity, serve as reference value and are set as 100%. Deviations from this reference are indicated as a difference in percent for the various materials. USTER PRODUCTS 13 (16)
14 RH% Cotton Wool / Silk Acetate Viscose Linen Polyamide Polyester Fig. 2 Influence of the relative humidity on the breaking force of yarns It is important for that tests are always made under the same conditions otherwise the results cannot be compared. There is an international standard called ISO 139 for the standard climate of a textile laboratory. This standard also demands that the material to be tested has to be exposed to the standard climate for a certain period so that the material to be tested adjusts itself to the standard temperature. All measurements should generally be made in this standard climate. Unfortunately this is not always possible due to practical reasons because a spinner wants to check his production as quickly as possible. This is often true for slivers whose evenness should be checked. In such cases it is possible to acclimatize the test samples to the standard climate as described above. As a rule, this process needs a minimum of 24 hours. There is a rule of thumb which says that the test samples should be measured immediately, in other words without waiting. If this second method is used, all further measurements have to be made in exactly the same manner. It is not advisable to switch between these two test methods because the results cannot be compared with one another. 14 (16) USTER PRODUCTS
15 8 Summary The test frequencies described in the chapters above should serve as a tool for the spinning mill. As each spinning mill is different, it may be that some adjustments have to be made. There may be cases where no online measurement can be carried out or certain test instruments are not available. The test frequencies described above assume an optimum situation. The size of a spinning mill may also require more or less tests that have to be adjusted accordingly. USTER PRODUCTS 15 (16)
16 Uster Technologies AG Wilstrasse 11 CH-8610 Uster / Switzerland Phone Fax sales@uster.com 16 (16) USTER PRODUCTS
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